Telwin 954009, Instruction Manual

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4.3 RECALLING AND STORING PROGRAMS

4.3.1 RECALLING MANUFACTURER’S PRE-STORED PROGRAMS 

4.3.1.1 MIG-MAG SYNERGIC programs

The welding machine is designed with “54”

 stored synergic programs, 

as specified 

in the table

 (TAB.3), which must be consulted when selecting a suitable program 

for the type of welding to be carried out.

A particular program is selected by pressing the “PRG” program repeatedly and the 

corresponding number, between “0” and “54” will be shown on the display (the number 

“0” does not have a corresponding synergic program but is for operating in manual 

mode, as described in the next paragraph).

Note: In a synergic program, it is essential to first select the desired transfer 

mode, PULSE ARC or SHORT/SPRAY ARC, using the appropriate key (see FIG.C 

(7)).

Note:

All types of wire that are not shown in the table can be used in manual 

mode “PRG 0”.

4.3.1.2 OPERATION IN MANUAL MODE (“PRG 0”)

Operation in manual mode corresponds to the number “0” on the display and is only 

active if the SHORT/SPRAY ARC transfer mode has been selected previously 

(see 

FIG.C (7)).

In this mode, as there will be no synergy, the operator should set all welding parameters 

manually.

Warning!

 The operator can set all the parameters freely therefore it is possible to set 

values that are incompatible with a correct welding procedure.

Note:  it  is  NOT  possible  to  use  PULSE  ARC  transfer  mode  when  manual  is 

selected.

4.3.2 STORING AND RECALLING CUSTOMISED MIG-MAG PROGRAMS

4.3.2.1 Introduction

The welding machine can be used to (SAVE) customised work programs relating to 

a set of valid parameters for a particular welding job. Each stored program can be 

recalled (RECALL) at any time so that the user finds the welding machine “ready-to-

use” for a specific job that has been optimised previously.

4.3.2.2 Storage capacity for customised MIG-MAG programs

The welding machine allows storage of customised programs in three groups that refer 

to the three synergic transfer modes (SHORT/SPRAY ARC Pulse arc and Pulse on 

pulse) and to manual mode operation, with the following specifications:

- SYNERGIC PULSE ARC PULSE ON PULSE: 10 programmes can be stored 

(available numbers from ”1” to ”10”),

-  SYNERGIC PULSE ARC: able to save 10 programs (available numbers from “1” to 

“10”),

-  SYNERGIC SHORT/SPRAY ARC: able to save 10 programs (available numbers 

from “1” to “10”),

-  MANUAL SHORT/SPRAY ARC (“PRG=0”): able to save 10 programs (available 

numbers from “1” to “10”).

To actually recall the program to be used, before selecting the number (as 

described  in  parag.  4.3.1), 

select  the  desired  transfer  mode:  PULSE  ARC, 

PULSE ARC  PULSE-ON-  PULSE  or  SHORT/SPRAY ARC  or  select  ”PRG=0”  if 

programmes have been pre-stored in manual mode.

4.3.2.3 Storage procedure (SAVE)

After adjusting the welding machine to carry out a particular weld perfectly, proceed 

as follows 

(see FIG.C)

:

a)  Press key

 (5) 

“SAVE”.

b)   “

Pr

” will appear on display 

(16)

 and a number (between “1” and “10”) on display 

(15)

.

c)  Turn the encoder knob (either 

(13) 

or 

(14)

) to select the number where the program 

is to be stored (see also 4.3.2 ).

d)  Press the “SAVE” key again.

e)  Displays 

(15) 

and

 (16)

 will flash.

f)   Within two seconds, press the “SAVE” key again.

g)  The displays will show “

St Pr

”, indicating that the program has been stored; 

after 2 seconds the displays will automatically switch to the values relating to the 

parameters that have just been saved.

Note. If the “SAVE” key is not pressed again within 2 seconds while the displays 

are flashing, they will show “

No St

” and the program will not be stored; the displays 

automatically return to what they were showing initially.

4.3.2.4 Procedure for recalling a customised program (RECALL)

Before proceeding to recall a program, make sure the selected transfer mode (PULSE 

ARC, 

PULSE ARC PULSE-ON-PULSE, 

SHORT/SPRY ARC or ”PRG=0”) is actually 

the one you intend to use.

Then proceed as follows 

(see FIG.C)

:

a)  Press the “RECALL” key.

b)  “

Pr

” appears on display 

(16)

 and a number (between “1” and “10”) on display 

(15)

.

c)   Turn the encoder knob (either 

(13) 

or 

(14)

) to select the number used to save the 

program that is to be used.

d)  Press the “RECALL” key again for more than 2 seconds.

e)  The displays will show “

Ld Pr

” indicating that the program has been loaded; after 2 

seconds the displays will automatically switch to the values relating to the program 

that has just been recalled.

  Note. If the “RECALL” key is not pressed again for longer than 2 seconds, the 

displays will show “

No Ld

” and the program will not be loaded; the displays 

automatically return to what they were showing initially.

NOTES:

-  DURING OPERATIONS WITH THE “SAVE” AND “RECALL” KEYS THE “PRG” 

LED IS ON.

-  A RECALLED PROGRAM CAN BE MODIFIED AS THE OPERATOR WISHES, 

BUT THE MODIFIED VALUES ARE NOT AUTOMATICALLY SAVED. TO SAVE 

THE NEW VALUES IN THE SAME PROGRAM IT IS NECESSARY TO FOLLOW 

THE STORAGE PROCEDURE (see 4.3.2.3).

-  THE USER IS RESPONSIBLE FOR RECORDING CUSTOMISED PROGRAMS 

AND THE RELATED MANAGING OF THE ASSOCIATED PARAMETERS.

-  CUSTOMISED PROGRAMS CANNOT BE SAVED IN TIG OR MMA ELECTRODE 

MODE.

5. INSTALLATION

WARNING!  CARRY  OUT  ALL  INSTALLATION  OPERATIONS  AND 

ELECTRICAL  CONNECTIONS  WITH  THE  WELDING  MACHINE 

COMPLETELY  SWITCHED  OFF  AND  DISCONNECTED  FROM  THE 

POWER SUPPLY OUTLET.

THE ELECTRICAL CONNECTIONS MUST BE MADE ONLY AND EXCLUSIVELY 

BY AUTHORISED OR QUALIFIED PERSONNEL.

5.1 PREPARATION

-  Unpack the welding machine;

-  Insert the polarisation connector if the GRA is not connected (FIG. D);

-  If there is a Trolley and/or GRA, consult their respective instruction handbooks.

5.2 HOW TO LIFT THE WELDING MACHINE (FIG. E)

The welding machine should be lifted without its removable parts (torch, gas pipes, 

cables etc.), which could come off in transit.

As shown in the illustration, assemble the attachment rings using the two M8x25 

screws provided.

Please note: eyelet rings for lifting, with threaded hole M8 UNI 2948-71, are not 

supplied.

5.3 POSITION OF THE WELDING MACHINE

Choose the place to install the welding machine so that the cooling air inlets and 

outlets are not obstructed (forced circulation by fan, if present); at the same time make 

sure that conductive dusts, corrosive vapours, humidity etc. will not be sucked into 

the machine.

Leave at least 250mm free space around the welding machine.

WARNING!  Position  the  welding  machine  on  a  flat  surface  with 

sufficient carrying capacity for its weight, to prevent it from tipping 

or moving hazardously.

5.4 CONNECTION TO THE MAIN POWER SUPPLY

5.4.1 Note

Before making any electrical connection, make sure the rating data of the welding 

machine correspond to the mains voltage and frequency available at the place of 

installation.

The welding machine should only be connected to a power supply system with the 

neutral conductor connected to earth.

To ensure protection against indirect contact use residual current devices of the 

following types:

-   Type A ( 

 ) for single phase machines;

-  Type B ( 

 ) for 3-phase machines.

To comply with the requirements of the EN 61000-3-11 (Flicker) standard we 

recommend connecting the welding machine to interface points of the power supply 

that have an impedance of less than Zmax = 0.283 ohm.

5.4.2 Plug and outlet

Connect a normalised plug (3P + T) having sufficient capacity to the power cable and 

prepare a mains outlet fitted with fuses or an automatic circuit-breaker; the special 

earth terminal should be connected to the earth conductor (yellow-green) of the power 

supply line. The table (TAB.1) shows the recommended delayed fuse sizes in amps, 

chosen according to the max. nominal current supplied by the welding machine, and 

the nominal voltage of the main power supply.

5.5 CONNECTION OF THE WELDING CABLES 

WARNING!  BEFORE  MAKING  THE  FOLLOWING  CONNECTIONS 

MAKE  SURE  THE  WELDING  MACHINE  IS  SWITCHED  OFF  AND 

DISCONNECTED FROM THE POWER SUPPLY OUTLET.

Table

 (TAB. 1) 

gives the recommended values for the welding cables (in mm

2

) .

5.5.1 MIG-MAG WIRE WELDING (FIG.F)

5.5.1.1 Connecting the gas bottle

-  Screw the pressure reducing valve onto the gas bottle, inserting the appropriate 

adapter supplied as an accessory when Argon or an Ar/CO

2

 mixture is used. 

-  Connect the gas inlet hose to the pressure reducing valve and tighten the supplied 

clip; then connect the other end of the hose to the connector provided on the back 

of the welding machine and tighten it with the supplied clip.

-  Loosen the adjustment ring nut on the pressure reducing valve before opening the 

gas bottle valve.

5.5.1.2 Connecting the torch

-  Engage the torch with its dedicated connector by tightening the locking ring nut 

manually as far down as it will go.

-  Prepare the wire for loading the first time, by dismantling the nozzle and the contact 

tip, to ease its exit.

-  Welding power supply cable to the quick connector (+).

-  Control cable to the corresponding connector.

-  Water pipes for R.A. versions (water-cooled torch) with quick connectors.

-  Make sure that the connectors are tightened properly so as to prevent overheating 

and reduced efficiency.

-  Connect the gas inlet hose to the pressure reducing valve and tighten the supplied 

clip; then connect the other end of the hose to the connector provided on the back 

of the welding machine and tighten it with the supplied clip.

5.5.1.3 Connecting the welding current return cable

-  This is connected to the piece being welded or to the metal bench supporting it, as 

close as possible to the join being made.

-  This cable is connected to the terminal with the symbol (-).

5.5.2 TIG WELDING (FIG. G)

5.5.2.1 Connection to the gas bottle

- Screw the pressure reducing valve onto the gas bottle valve, inserting the 

appropriate adapter supplied as an accessory, for when the gas used is Argon or an

  Argon /CO

2 

mixture.

-  Connect the gas inlet pipe to the pressure-reducing valve and tighten the band 

supplied; 

then connect the other end of the pipe to the connector on the back of the 

welding machine and tighten it using the band supplied.

-  Loosen the adjustment ring nut on the pressure-reducing valve before opening the 

bottle valve.

5.5.2.2 Connecting the welding current return cable

-  This is connected to the piece being welded or to the metal bench supporting it, as 

close as possible to the join being made.

-  This cable is connected to the terminal with the symbol (+).

5.5.2.3 Connecting the torch

-  Connect the TIG torch to the quick connection (-) on the front panel of the welding 

machine; complete the connection of the gas pipe and torch control cable.

5.5.3 MMA WELDING WITH COATED ELECTRODE (FIG. H)

5.5.3.1 Connecting the electrode-holder clamp

Practically all coated electrodes are connected to the positive pole (+) of the power